2004 6.0 is stuttering upon accelerating at stop lights. Or when in overdrive and starting up a hill, or under a load hauling a trailer etc. It's sounds like the EGR again, but I've cleaned it again, put on new O-rings. Last time I cleaned it, it wasn't that dirty and it wasn't stuck. But I cleaned again and reinstalled. Also, it might be me, but it seems as though it gets worse when fuel is low. If it's not EGR what else can it be? Also it smokes a little when this happens as well. Most of the time it's black smoke, but it has been white also. Just a big puff an then I'm good to go.

if you pull on the pintle of the egr, it should spring right back into its bore. sometimes the shaft of the pintle binds internally = bad egr valve. Your problem sounds like a fuel pressure or faulty injector(s)

What can happen is carbon builds up in the egr cooler/intake mainfold, and the carbon can eventually flake off and momentarily hang a valve. That is something that would happen intermittently, and would be impossible to duplicate at will, and would probably happen once /week-month. If your truck does it all the time, i would suspect fuel injector/fuel pressure/FICM MPower. If pump whines, it would be worth pulling the filter from the framerail pump and seeing if the outer-layer has "wrinkles" in it, causing a restriction.

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